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    Thread: AJmustDIE's ABA Turbo Build Thread

    1. Member AJmustDIE's Avatar
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      97 Black GLX, RIP 97 White 8vT Jetta Trek
      03-26-2011 10:07 PM #1
      What's up guys, very recently I blew my transmission in my MKIII.
      Sooo, I'm taking the time I have now to take this thing apart (somewhat) and install the part's I've had stacked against my bedroom wall for months now.

      The canvas is an already "slammed" Trek on Miro STP-1 Wheels. All work thus far been done by myself.



      Official "Before" Photo.


      This is how the primary setup is going to be.

      Garrett GT2541r Dual BB Core Oil & Water-cooled Turbo GT2876r
      • Frozenboost 600hp Air/Water Intercooler Kit (No I'm not trying to push that number)
      • 2.5" Polished Charge Piping
      • MK4 2.0 Manifolds and corresponding parts.
      • C2 Stage 2 Software
      • Bosch 42lb Green Top Injectors

      When the build is over I'm swapping out the blown 020 Tranny for an 02A to give me peace of mind and for better gearing.

      Also, I will only be running 8 PSI when the build is "completed" after I get the tranny paid for I'm buying a set of JE pistons and IE rods to lower my compression so I can raise the boost. Just so your minds don't wander..

      Day One of Build, Deconstruction Time.

      Sittin' down takin' a break before I get at it, garage view.


      Stock MK3 Upper Manifold Off


      Stock Fuel Rail pulled off, probably going to be re-used.


      Myself taking the time to pose for a 10 sec timer pic,


      MK3 Lower Intake manifold, so damn restrictive.


      Shot of the head & cam. Wish I had the money to go to a more aggressive cam but that will come later.


      Pile of USELESS junk.


      End of Day 1,

      -------------------------------------------

      Day 2

      Here's a peak what the bay is going to be looking like , took about 10-15 hours polishing the AEG Upper Intake.


      Here's the baby of a Turbo I'll be workin' with.


      Stay tuned men, I'm 19 years old and I'll be doing ALL of the work myself. This is my first turbo build and first time working with a VW's engine. I've got a pretty solid background on what I'm doing. Sub if you support boosted ABA's
      Last edited by AJmustDIE; 09-15-2011 at 05:41 PM.
      Quote Originally Posted by root beer View Post
      It's Timmy with mmmmMojo, i have returned
      8VALVETURBO - RIP White Jetta

    2. Member vibrancyy's Avatar
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      03-26-2011 10:28 PM #2
      Subscribed! Good luck with this! white jetta

    3. All Star
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      03-26-2011 10:32 PM #3
      i used to have a white ABA turbo Jetta.

      I miss that pig.

      Good luck Mang.
      -Tom-
      BBDrB
      FS: Garage Clean Out

    4. Member fukdapo9's Avatar
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      #9 Sold Waiting on #10
      03-26-2011 10:58 PM #4
      watching
      Quote Originally Posted by Myzteriuz View Post
      on some thread a guy said you'll blow seam seals and ruin your transfuser brackets?
      Quote Originally Posted by stewie griffin View Post
      i dont how to JB weld.

    5. Banned vento86's Avatar
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      03-26-2011 11:01 PM #5
      aba turbos are fun!! good luck with the project.

    6. Member MKIIITOMV's Avatar
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      03-26-2011 11:10 PM #6
      awesome build deff watching this

    7. Member jbigs268's Avatar
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      03-26-2011 11:31 PM #7
      i shall follow this one!
      Quote Originally Posted by 95jetta17 View Post
      not again 11/11/11 never forget
      Quote Originally Posted by vento86 View Post
      anyone got anymore pics of that yellow gti?
      Yellowlove

    8. Member AJmustDIE's Avatar
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      03-27-2011 08:14 PM #8
      Alrighty guys.
      Made some progress today in regards to the turbo it's self, more specifically the manifold.

      I was being curious to how well the gasket matched up to the turbo manifold yesterday so I lined it up and holy bahjesus. One look and I could tell some gasket matching needed to be done.


      (yes I realize the gasket it upside down but that is irrelevant)

      Stuck the gasket to the mani and laid some paint down, and got to work!


      Good amount of material shaved out.


      After correcting some misshapen bumps and such, wahhlahhh!


      And the other side.



      Now I realize this is not much of an update. But it was critical none the less, those faces on the turbo manifold could have hindered some performance so I know what little time I spent doing this is well worth it. Finished that up, cleaned up and snapped a pic of the Jetta.. I miss her face



      On the plus side my buddy picked me up this sweet decal off of ebay



      That is all for today.
      Quote Originally Posted by root beer View Post
      It's Timmy with mmmmMojo, i have returned
      8VALVETURBO - RIP White Jetta

    9. Banned vento86's Avatar
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      03-27-2011 08:21 PM #9
      That 2slow decal is awesome. I'm getting one for my mk1 abat

    10. Member AJmustDIE's Avatar
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      97 Black GLX, RIP 97 White 8vT Jetta Trek
      03-27-2011 08:25 PM #10
      Quote Originally Posted by vento86 View Post
      That 2slow decal is awesome. I'm getting one for my mk1 abat
      I wanna see
      Quote Originally Posted by root beer View Post
      It's Timmy with mmmmMojo, i have returned
      8VALVETURBO - RIP White Jetta

    11. Banned vento86's Avatar
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      03-27-2011 08:30 PM #11
      Quote Originally Posted by AJmustDIE View Post
      I wanna see
      Build thread is in my sig but my photobucket account sucks right now and the pics don't work

    12. Junior Member DUBSKEE's Avatar
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      03-27-2011 08:31 PM #12
      watching this

    13. Member A3jett's Avatar
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      03-27-2011 09:56 PM #13
      liking this build

    14. Member
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      03-27-2011 11:51 PM #14
      Quote Originally Posted by AJmustDIE View Post
      Sub if you support boosted ABA's
      im building one myself right now
      Quote Originally Posted by Saves View Post
      hes probably still sitting in his drivers seat slouched over, unconcious after trying to pull straight up so hard on the shift knob that his hand slipped off, whacking him in the face hard enough to put him to sleep for 4-6 hours.
      Quote Originally Posted by root beer View Post
      I'm going to ruin all of your internet lives.

    15. Member AJmustDIE's Avatar
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      03-28-2011 12:01 AM #15
      Quote Originally Posted by vento86 View Post
      Build thread is in my sig but my photobucket account sucks right now and the pics don't work
      Looks like they're working fine to me! And hot damn! Have you any fingerprints left with all that sanding!? lol.

      Sick dude, watching your build now. Wish I had the time to pull mine apart and attack my bay, but that's for another day. I need this damn thing back on the road ASAP. SOWO is commin' around fast!
      Quote Originally Posted by root beer View Post
      It's Timmy with mmmmMojo, i have returned
      8VALVETURBO - RIP White Jetta

    16. Member jettaiv4turbochrg's Avatar
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      03-28-2011 12:03 AM #16
      nice
      Team Foreign Objects Maui Style!

      #146--jettaiv4turbochrg---2000 VW Jetta GL---boosted AEG, B&G coilovers, 18" Brocks, C2 software

    17. Banned vento86's Avatar
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      03-28-2011 12:59 AM #17
      Quote Originally Posted by AJmustDIE View Post
      Looks like they're working fine to me! And hot damn! Have you any fingerprints left with all that sanding!? lol.

      Sick dude, watching your build now. Wish I had the time to pull mine apart and attack my bay, but that's for another day. I need this damn thing back on the road ASAP. SOWO is commin' around fast!
      I JUST upgraded to PB PRO.. and my fingas' hurt! And shaving bays are no joke. It takes a LOT of time. And thanks brotha! Lol

    18. 03-28-2011 02:35 AM #18
      If you are swapping the trans, and installing all the FI related components, just pull the front clip, then pull the entire engine/trans as a unit. You will save a TON o/f time and a TON of frustration.




      for doing work.

    19. Member AJmustDIE's Avatar
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      97 Black GLX, RIP 97 White 8vT Jetta Trek
      03-28-2011 02:50 AM #19
      Quote Originally Posted by JohnStamos View Post
      If you are swapping the trans, and installing all the FI related components, just pull the front clip, then pull the entire engine/trans as a unit. You will save a TON o/f time and a TON of frustration.




      for doing work.
      I'm gonna throw this turbo setup together and let my buddy who's gonna tackle the transmission worry about that I have to drive it to his garage after I get the engine running. It's stuck in 3rd gear. lol. But yeah man I'd figured as much. Thanks for lookin' out!
      Quote Originally Posted by root beer View Post
      It's Timmy with mmmmMojo, i have returned
      8VALVETURBO - RIP White Jetta

    20. Member nfx's Avatar
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      03-28-2011 05:36 AM #20
      for another 2.0T

      I just installed an AEG manifold myself. what is your plan for dealing with the larger then normal holes for the injectors on the lower manifold?
      2.0T... it's back!

    21. Member 2point0jetta's Avatar
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      03-28-2011 09:25 AM #21
      That AEG swap is sexy. Keep up the good work.
      .:Urostyles
      MKIII Kickball M.V.P. of the Year 2011
      Quote Originally Posted by reynolds9000 View Post
      Seth is the Babe Ruth of kickball.

    22. Member AJmustDIE's Avatar
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      03-29-2011 02:51 AM #22
      Quote Originally Posted by nfx View Post
      for another 2.0T

      I just installed an AEG manifold myself. what is your plan for dealing with the larger then normal holes for the injectors on the lower manifold?
      May I see a picture of your setup?

      I Unclipped the plastic clip that came on the #42 Injectors, doubled up the rubber o-rings and pushed it in, looks like it's sealing fine but we'll find out when I turn the key and both fuel pumps come on. lol.

      In other news, I just bought a welder today. It's nothing special just something to get me by when I come to mounting all the Air/Water Intercooling components. Should have some pics tomorrow of some more progress if it's not raining.
      Quote Originally Posted by root beer View Post
      It's Timmy with mmmmMojo, i have returned
      8VALVETURBO - RIP White Jetta

    23. Member croutonjack's Avatar
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      03-29-2011 03:48 AM #23
      here's a birch beer for you since you're underage

    24. Member AJmustDIE's Avatar
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      03-29-2011 04:44 AM #24
      Quote Originally Posted by croutonjack View Post
      here's a birch beer for you since you're underage
      Age didn't stop me when I was in the Army for 2 years.
      Damn hernia..
      Quote Originally Posted by root beer View Post
      It's Timmy with mmmmMojo, i have returned
      8VALVETURBO - RIP White Jetta

    25. Member nfx's Avatar
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      03-29-2011 05:34 AM #25
      Only real picture I have of the bay... before paint.



      The only thing I'd change from this setup is the IAT. I was in a rush so I welded a nut onto a pipe and threw it in there.

      Here is my new fix...



      1.8T IAT sensor. You can drill 2 holes... tap one for a bolt... grab an o-ring... install and enjoy. Not only is that easier, the 1.8T sensor gets more accurate readings due to the open air element (no heatsoak like the MK3 2.0/VR model)
      Last edited by nfx; 03-29-2011 at 06:36 AM.
      2.0T... it's back!

    26. Member jordan_fehlman's Avatar
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      03-29-2011 06:08 AM #26
      yum
      I hang out in the classifieds

    27. Member AJmustDIE's Avatar
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      03-29-2011 06:44 AM #27
      Looks good man, get that upper polished!

      Whats your system specs?
      Quote Originally Posted by root beer View Post
      It's Timmy with mmmmMojo, i have returned
      8VALVETURBO - RIP White Jetta

    28. Member nfx's Avatar
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      03-29-2011 08:31 AM #28
      Already started the polishing project... most of the pipes are now polished (not as well as I want, but I'll get there). Manifold is a different story... that'll probably be done next winter.

      As far as a setup... nothing too special

      rebuilt Garrett T3 .52 trim (.48 hotside)
      2-1/2 downpipe back with a highflow cat
      FMIC (obviously) with 2-1/4 piping all around
      AEG manifold (obviously)
      Bosch red tops (30lbers) with C2 stage 1 software (from summer 2007... I think it's ver. 2 software)
      Pushing around 11psi - close to 200whp i assume... haven't dyno'd in a while
      Autotech 260 cam with lightweight lifters... everything else motor wise is stock
      ACT stage 1 clutch (slipping)
      BFI Stage .5 motor mount inserts

      I've got a clutchnet unit to replace the ACT clutch, along with a new rear main seal and possibily a bolt kit too for the 02O. I'd go stand alone, but the car has to pass plug-in OBD2 emissions where im living, so PNP software is a must and i want stage 2. I'd also love to do some head work... but money is tight, so yeah.

      plans for the spring/summer include fixing my leaky exhaust, changing the clutch and associated parts i mentioned earlier, and driving it.

      edit: picture of the car

      Last edited by nfx; 03-29-2011 at 08:36 AM.
      2.0T... it's back!

    29. Member raymondlee's Avatar
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      03-29-2011 04:33 PM #29
      hey man sick build

    30. Member AJmustDIE's Avatar
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      03-29-2011 04:43 PM #30
      Quote Originally Posted by raymondlee View Post
      hey man sick build
      Thanks man!


      Thought I would share a photo of my intercooler setup with you guys.


      If anybody has any questions about the Air/Water setup, I'll be glad to answer them for you.
      Quote Originally Posted by root beer View Post
      It's Timmy with mmmmMojo, i have returned
      8VALVETURBO - RIP White Jetta

    31. Junior Member ItAintRubbinItAintDubbin's Avatar
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      03-29-2011 04:51 PM #31
      now that water is going to be sprayed through the cooler to lower the air temp passing through right?

    32. Member AJmustDIE's Avatar
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      03-29-2011 05:02 PM #32
      Quote Originally Posted by ItAintRubbinItAintDubbin View Post
      now that water is going to be sprayed through the cooler to lower the air temp passing through right?
      Yes , A Water to Air Intercooler setup is similar in principle to a traditional air to air setup, except that there is water passing through the core of the intercooler instead of air which is responsible for drawing the heat out of the intake air. Water and other coolants disperse heat faster and more efficiently than air can.

      After the water makes it's way out of the intercooler it's been heated, it then goes through the Air/Water heat exchanger, it's basically a radiator, as the water moves through the heat exchanger it cools back to ambient air temps. Then it makes it's way to the Ice box, which mine personally will always be filled with chunks of ice, even though the ice box isn't necessary for the setup, you can clearly think of the benefits of passing 40 degree water through the Intercooler
      Quote Originally Posted by root beer View Post
      It's Timmy with mmmmMojo, i have returned
      8VALVETURBO - RIP White Jetta

    33. Member nfx's Avatar
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      03-29-2011 06:20 PM #33
      hey hey now i see an all aluminum radiator. what'd you find that worked?
      2.0T... it's back!

    34. Member Dmoneythegreat's Avatar
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      03-29-2011 06:21 PM #34
      Making me want to keep my 8v and turbo it instead of doing a 16v turbo
      Goodluck
      I hope you take videos of it running when it's finished
      Quote Originally Posted by krazy eyez killa View Post
      Coming from the fact that you and ho-bro are from the stanceworks forums, there's not one inch of stance in any of these cars. both your ****'s weak, go back to the drawing board because your futile attempt in getting recognition failed miserably. go back to stanceworks and swing on mike burrough's sweaty nuts more. pussies.

    35. Junior Member MM2 Zayas's Avatar
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      03-29-2011 07:02 PM #35
      Keep it up, 8v is just classier. Cheers

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